Apprenticeship Training Standard. Motorcycle Technician. Trade Code: 310G

Transcription

1 ship Training Standard Motorcycle Technician Trade Code: 310G Development : October 2003

2 Please Note: ship Training and Curriculum Standards were developed by the Ministry of Training, Colleges and Universities (MTCU). As of April 8th, 2013, the Ontario College of Trades (College) has become responsible for the development and maintenance of these standards. The College is carrying over existing standards without any changes. However, because the ship Training and Curriculum Standards documents were developed under either the Trades Qualification and ship Act (TQAA) or the ship and Certification Act, 1998 (ACA), the definitions contained in these documents may no longer be accurate and may not be reflective of the Ontario College of Trades and ship Act, 2009 (OCTAA) as the new trades legislation in the province. The College will update these definitions in the future. Meanwhile, please refer to the College s website ( for the most accurate and up-to-date information about the College. For information on OCTAA and its regulations, please visit:

3 CONTENTS PAGE ship Program Summary/Guidelines...3 Competency Analysis Profile...6 Preface...16 Definitions...17 Important Directions for the...19 Important Directions for the Sponsor/Employer and...19 Notice/Declaration for Collection of Personal Information...20 Roles and Responsibilities of the, Sponsor/Employer, and...21 Skill Set Completion Form...23 SKILL SETS U Protect Self and Others...25 U Apply General Work Practices and Procedures...31 U Perform Preliminary Diagnosis...35 U Diagnose and Repair Two-Stroke and Four-Stroke Engine (Mechanical)...38 U Diagnose and Repair Fuel Carburation System...49 U Diagnose and Repair Fuel-Injection System...57 U Diagnose and Repair Cooling System...63 U Diagnose and Repair Exhaust System...67 U Diagnose and Repair Driveline...71 U Diagnose and Repair Steering System...79 U Diagnose and Repair Front Suspension...83 U Diagnose and Repair Rear Suspension...86 U Diagnose and Repair Mechanical Braking System...90 U Diagnose and Repair Hydraulic Braking System...95 U Diagnose and Repair Tires and Wheels...99 U Diagnose and Repair Charging System

4 U Diagnose and Repair Electric Starting System U Diagnose and Repair Ignition System U Diagnose and Repair Electrical Ancillaries U Diagnose and Repair Chassis and Chassis Components U Service Body Parts U Diagnose and Repair Sidecar Record Completion Form

5 APPRENTICESHIP PROGRAM SUMMARY/GUIDELINES 1. Program Definition: Motorcycle Technician is defined as a person who: services, repairs, overhauls, and inspects motorcycles and tests them for faults and roadworthiness. MOTORCYCLE TECHNICIAN is an approved apprenticeship program for the purposes of the ship and Certification Act, 1998 (ACA). 2. Program Guidelines On-the-Job Training Duration (for apprentices) The Industry Committee has identified 5520 hours as the duration generally necessary for any apprentice to become competent in the skills required. There may be individual circumstances in which the duration varies from this guideline. In-School Training Duration The Industry Committee has identified 480 hours of in-school training as the duration generally necessary for an apprentice to complete the in-school curriculum for this program, except where an apprentice has been exempted from any level of that curriculum. Ratio The Industry Committee has identified a journeyperson-to-apprentice ratio of one journeyperson or individuals who are deemed equivalent to a journeyperson status to one apprentice as the ratio generally necessary for an apprentice to be properly trained on the job in this program. There may be individual circumstances in which the ratio varies from this guideline. 3

6 3. Program Requirements Restricted Skill Sets This program contains one or more restricted skill sets as per Ontario Regulation 565/99, Restricted Skill Sets. An individual must either be a registered apprentice or possess a Certificate of Qualification or Letter of Permission in this program in order to perform skills contained within it. Academic Standard The Industry Committee has identified the minimum academic standard for entry to this program as completion of Grade 12 or ministry-approved equivalent. (See ACA Policy 102, Confirming Academic Requirements.) Eligibility for Exam Challenge (for Non-apprentice C of Q Applicants) The challenger must: provide proof of competency in all mandatory (unshaded) skills as identified in the Training Standard or Schedule of Training; demonstrate that he or she has acquired 6000 hours of on-the-job training. (See ACA Policy 150, Assessing Applicants for the Certificate of Qualification.) Eligibility for Program Completion (for s) The apprentice must: achieve competency in all mandatory (unshaded) skills as identified in the Training Standard or Schedule of Training; complete the in-school training as outlined in the industry and ministryapproved Curriculum Standard. (See ACA Policy 309, Completion of an ship Program.) Other Resources Complete program requirements, policies, and standards can be obtained by referring to the following resources: ship and Certification Act, 1998 (ACA) ACA General Regulation 573/99 ACA Exemption Regulation 566/99 Program-specific ship Training Standards or Schedules of Training ACA Program and Policy Manual Other Required Certification N/A 4

7 Academic Background Industry has identified relevant secondary-school course(s) likely to increase an individual s chances of success if completed before program entry. For details, see the document ship Subject Pathways. 5

8 COMPETENCY ANALYSIS PROFILE Motorcycle Technician 310G (All unshaded skill sets must be demonstrated/completed.) SKILL SETS SKILLS PROTECT SELF AND OTHERS Identify health and safety hazards in the workplace Wear, adjust, and maintain personal protective equipment Operate emergency safety equipment Practise good housekeeping in the workplace Operate and maintain tools and equipment in a safe manner U U U U U U Ensure protection Report injuries to Apply basic first aid from fire hazards supervisor Handle and store hazardous materials Complete written safety and injury reports U U U U U Identify unsafe vehicles U

9 APPLY GENERAL WORK PRACTICES AND PROCEDURES Perform preliminary diagnosis Select, operate, and maintain oxyacetylene arc, metal inert gas (MIG), and tungsten inert gas (TIG) welding equipment Access information in manufacturers service manuals and other related service materials Select, operate, and maintain hand, cutting, pneumatic, and electric power tools Operate and maintain shop equipment Operate and maintain dimensional measuring devices U U U U U U Replace fastening Perform customer and sealing devices relations activities Select and replace or repair electrical wires and connectors Demonstrate troubleshooting techniques U U U U U Perform proper dismantling, logging, protection, and storage of parts Document measurements and defects noted during inspection U U PERFORM PRELIMINARY DIAGNOSIS Conduct visual examination of motorcycle Conduct a road test Isolate problem to a specific part of the motorcycle Prepare preliminary written estimates Prepare a written work order U U U U U U

10 DIAGNOSE AND REPAIR TWO-STROKE AND FOUR- STROKE ENGINE (MECHANICAL) Perform a visual inspection of engine externals Perform a visual inspection and functionally test oil-injection pump Listen to engine using an engine stethoscope Remove spark plugs Conduct compression and leak-down test Conduct crankcase pressure test U U U U U U Remove and Resurface Remove cylinder visually inspect cylinder heads block from crankcase cylinder heads Perform a visual inspection of cylinder components Chamfer cylinder ports Remove accumulated exhaust carbon from cylinder heads U U U U U Clean and measure Resleeve and Deglaze cylinder cylinder resize cylinder bore components Perform a visual inspection and physically measure intake reed valves and exhaust power valves U U U U U Check and adjust Remove engine Disassemble piston ring end gap from frame engine Disassemble, visually inspect, clean, and measure crankshaft components U U U U U Perform a visual inspection of intake rotary valves Perform a visual inspection of crankcases, support bearings, and bushings Replace crankshaft components Perform a visual inspection of counterbalancer components Install counterbalancer and crankshaft in engine crankcases U U U U U Reinstall intake rotary valve in crankcase Reinstall internal cylinder components Reinstall engine in motorcycle frame Bleed air from and adjust oilinjector pump Replace fluids U U U U U Perform final adjustments U

11 DIAGNOSE AND REPAIR FUEL CARBURATION SYSTEM Perform a visual inspection for sufficient fuel quantity and quality Perform test to ensure fuel is of correct type Perform a visual and physical inspection of fuel venting systems Perform a visual inspection of air filters and air box Test operation of petcock U U U U U U Inspect and repair or replace fuel lines and filters Perform functional tests of fuel pump operation Replace fuel pump Test and repair fuel pump electrical circuit components Perform a visual inspection and functionally test carburettor control linkage and cables U U U U U Remove, replace, and adjust carburettor cables and control linkages Perform a visual inspection and functionally check mounting and condition of intake manifolds and fittings Remove carburettor from manifold Disassemble carburettor Perform a visual inspection of and clean float bowl U U U U U Clean and perform Clean and Clean, perform a Reassemble a visual inspection perform a visual visual inspection carburettor of pilot, inspection of of, and replace components intermediate, and accelerator pump carburettor main jets, and fuel components venturi system and air passages in components carburettor body Perform functional tests, and replace and adjust float, needle, needle seat, and float bowl vent U U U U U Adjust carburettor Install carburettor on intake manifolds U U

12 DIAGNOSE AND REPAIR FUEL- INJECTION SYSTEM Perform a visual inspection for sufficient fuel quantity and quality Perform a test to ensure fuel is of correct type Perform a visual inspection of air filters and air box Perform a physical inspection of fuel tank components Perform a physical inspection of fuel lines, in-line filters, hoses, and fittings U U U U U U Test fuel pump operation and fuel pressure regulation system Replace fuel pump pressure regulation valve, hoses, fittings, fuel pump lines, and electrical components Test fuel pump electrical circuits Inspect and replace cables and linkages Inspect and functionally test intake manifold, fittings, and vacuum hoses U U U U U Perform functional test of injector Remove and perform a physical inspection of injector body Replace injectors Compare fuelinjector computer codes with service manual Perform inspection of fuel-injector control system components U U U U U Repair and replace injector control system components U DIAGNOSE AND REPAIR COOLING SYSTEM For air-cooled engine perform a visual inspection for damaged fins and proper air flow and remove restriction For liquid-cooled engine perform a visual inspection of cooling system components Perform functional test of coolant strength and quantity in radiator Perform pressure test of cooling system components Test cooling system controls U U U U U U Replace cooling system components Check, replace, and rebuild water pumps and drives Flush, bleed, and refill cooling system U U U DIAGNOSE AND REPAIR EXHAUST SYSTEM Perform a visual inspection of exhaust system Perform an audible inspection of exhaust system Disassemble and decarbonize exhaust system components Disassemble, inspect, and repair exhaust power valve components Repair or replace exhaust system components U U U U U U

13 DIAGNOSE AND REPAIR DRIVELINE Perform a visual and physical inspection Inspect clutch activating mechanism Adjust clutch cable/linkage freeplay Expose and inspect primary drive components Reassemble primary drive components U U U U U U Disassemble, clean, and visually inspect clutch components Reassemble and install clutch assembly, replacing defective components Perform operational tests of kick-starter Replace, lubricate, and reassemble kickstarter components Inspect external shifter mechanism U U U U U Perform a visual Perform a visual inspection of outer inspection of inner transmission case transmission case Replace, lubricate, and adjust external shifter mechanism Expose, disassemble, and inspect transmission internal parts Clean and measure transmission components U U U U U Lubricate, replace, and reassemble transmission components Expose and perform a visual inspection of final chain/belt drive Disassemble, replace, and adjust chains, sprockets, belts, and pulleys Inspect and replace front bevel gears Inspect and replace driveshaft assembly components U U U U U Disassemble, clean, and inspect final drive housing components Lubricate, replace, reassemble, and adjust final drive components U U DIAGNOSE AND REPAIR STEERING SYSTEM Inspect front-end and frame components visually and physically Functionally test steering stops and steering lock Adjust steering head bearing and front wheel bearings Disassemble and inspect steering head components Repair or replace and assemble steering head components U U U U U U Inspect or replace hydraulic steering friction dampeners U

14 DIAGNOSE AND REPAIR FRONT SUSPENSION Perform a visual inspection Perform operational test of front suspension system hydraulic and pneumatic anti-dive mechanisms Disassemble, inspect, and measure front fork assembly components Replace or reassemble fork assembly components Inspect and functionally test and repair air compressor system and components U U U U U U Identify and service front suspension system Perform suspension sag measurements U U DIAGNOSE AND REPAIR REAR SUSPENSION Inspect rear suspension components Disassemble, clean, and inspect rear suspension components Inspect and replace or rebuild shocks Replace rear suspension components and reassemble Perform suspension sag measurements U U U U U U Inspect, test, adjust, and replace auto levelling system components Align back wheel to front wheel U U DIAGNOSE AND REPAIR MECHANICAL BRAKING SYSTEM Perform a visual and an operational inspection of brake levers, cables, and linkages Lubricate, adjust, and replace, linkages, cables, and levers Remove wheels Remove, clean, and perform visual inspections of internal and external brake components Measure brake system components U U U U U U Rebuild and replace mechanical calipers Replace friction material on brake shoes in calipers Resurface brake drums and discs Replace and adjust drums, rotors, and friction materials on wheels Reassemble, lubricate, and adjust mechanical braking systems U U U U U

15 DIAGNOSE AND REPAIR HYDRAULIC BRAKING SYSTEM Perform a visual and physical inspection Remove, rebuild, or replace master cylinders, wheel cylinders, and calipers Remove and replace brake fluid proportioning valve Identify the requirement of care and attention to the usage or spillage of brake fluid Remove and replace brake lines, banjo bolts, and crush washers U U U U U U Measure and inspect brake drums and discs Inspect and test anti-lock braking system Flush, replenish, and bleed fluids Measure and replace disc brake pads and friction material on brake shoes Replace and adjust anti-lock braking system components U U U U U Adjust lever freeplay at master cylinder U DIAGNOSE AND REPAIR TIRES AND WHEELS Perform a visual and physical inspection of tires Inspect and test wheels Remove, clean, and inspect internal wheel and hub components Lubricate and reassemble hub components Clean and inspect tire and rim components U U U U U U Remove, replace, and adjust tension of spokes Install tire on rim Balance wheel assembly Replace tire/wheel assembly U U U U DIAGNOSE AND REPAIR CHARGING SYSTEM Perform a visual inspection of wiring connectors and fuses Inspect, clean, identify, and test battery Charge or replace battery Test alternating current generator Repair wiring and connections U U U U U U Test regulator/rectifier U

16 DIAGNOSE AND REPAIR ELECTRIC STARTING SYSTEM Inspect and clean battery, power, and ground wiring and connectors Identify battery, type 1 charges, and load test, and replace battery Perform functional tests of starting system components Repair or replace switches, solenoids, and starter relays Disassemble, clean, and measure starter components U U U U U U Repair or replace starter motor components Replace mechanical starter drive components Assemble and lubricate starter system components U U U DIAGNOSE AND REPAIR IGNITION SYSTEM Inspect and clean battery, power, and ground wiring and connectors Charge, load test, and replace battery Identify and test power source to ignition Test for spark at plug(s) Test and replace high-tension leads and spark plug cap U U U U U U Test and replace ignition coils Test and repair wiring and connectors Inspect and replace points and condenser Inspect, lubricate, or replace ignition advance system and components Adjust timing of breaker-point ignition system U U U U U Test and replace Test and replace pick-up coil on ignition module electronic ignition and related wiring Adjust air gap on pick-up coil on electronic ignition Adjust and clean timing of electronic ignition system DIAGNOSE AND REPAIR ELECTRICAL ANCILLARIES U U U U Charge, load test, and replace batteries Inspect and clean battery, power, and ground wiring and connectors Perform visual and functional tests of fuses, circuit breakers, and fusible links Isolate and repair opens, shorts, and grounds in wiring and connectors Test ancillary operating switches U U U U U U Repair or replace accessory operating switches Test and replace defective ancillaries U U

17 DIAGNOSE AND REPAIR CHASSIS AND CHASSIS COMPONENTS Perform a visual inspection of chassis components Perform functional test of frame and suspension alignment Replace chassis and chassis components U U U U SERVICE BODY PARTS Perform a visual inspection of body parts Disassemble and correctly store body parts Perform a visual inspection and identify body part hardware Repair or replace body part hardware Repair or replace body parts U U U U U U Replace body parts U DIAGNOSE AND REPAIR SIDECAR Measure and perform a visual inspection of sidecar unit, frame, mountings, and alignment Perform functional tests and repairs to sidecar braking systems Align sidecars to motorcycle frame Repair or replace sidecar components Reassemble, lubricate, and adjust sidecar components U U U U U U

18 PREFACE This training standard was developed by the Workplace Training Branch of the Ministry of Training, Colleges, and Universities (MTCU), in partnership with the Industry Committees and in consultation with representatives from the industry. This document is intended to be used by the apprentice, supervisor/trainer, and sponsor/employer as a blueprint for training and as a prerequisite for completion and certification. This training document becomes the apprentice s only record of workplace training performance. The supervisor/trainer and apprentice are required to sign off on and date the skills following each successful acquisition, unless a skill is marked shaded (optional). The care and maintenance of this training document are the joint responsibility of the apprentice and the sponsor/employer. By signing off on the skill, the supervisor/trainer and the apprentice are indicating that the apprentice has demonstrated competence in the skill. This training standard has been developed specifically for documenting the apprentice s acquisition of skills of the trade. 16

19 DEFINITIONS ACA ship and Certification Act, 1998 Certificate of ship (C of A) Certification issued to individuals who have demonstrated that they have completed an apprenticeship in Ontario Certificate of Qualification (C of Q) Certification issued to C of Q applicants who have achieved a passing grade on the certification exam for their trade Competency Analysis Profile A document that identifies the training needs of an individual trade and details the skills/skill sets that must be demonstrated Competence The ability of an individual to perform a skill repeatedly and without assistance in the workplace to the standard set out in the Training Standard or Schedule of Training General Performance Objective (On-the-Job Skill Set) Describes a set of skills that includes all performance objectives under that skill set Industry Committee (IC) Under the ACA and Provincial Advisory Committee (PAC) Under the TQAA Under the ACA and TQAA, the Minister may appoint a provincial committee in any trade or group of trades to advise the Minister in matters relating to the establishment and operation of apprenticeship training programs and trades qualifications. Journeyperson or Equivalent A person who has acquired the knowledge and skills in a trade, occupation, or craft as attested to by a provincial or territorial authority Mandatory Status assigned to unshaded individual skills, skill sets, or general performance objectives that must be signed off on for the apprentice to complete the program Optional Status assigned to shaded individual skills, skills sets, or general performance objectives for which sign-off is not required for the apprentice to complete the program but that may be tested on an examination for certification Sign-Off 17

20 Signature of the sponsor/employer of record or an individual to whom that sponsor or employer has delegated signing authority, indicating an apprentice s achievement of competence Skill Individual skill described in the Training Standard (note: does not mean the larger skill groups referred to in the Training Standard as Skill Sets, Training Units, or General Performance Objective, but the individual skills that make up those groups) Skill Sets Group of individual skills found in the Training Standard (may also be called Training Unit or General Performance Objective) Skill Set Completion Form Lists all skill sets and includes space for sign-off by sponsor/employer of record Sponsor/Employer A person who has entered into a registered training agreement under which the person is required to ensure that an individual is provided with workplace-based training in a trade, other occupation, or skill set as part of an apprenticeship program approved by the Director Sponsor/Employer of Record Refers to the sponsor or employer documented as the signatory to the current training agreement or contract. For sponsors/employers to be considered for the training of apprentices, they must identify that the workplace has qualified journeypersons or equivalent on site and can identify that the workplace has the tools, equipment, materials, and processes that have been identified by Provincial Advisory Committees (PACs) or Industry Committees (ICs) as being required for the trade. Supervisor An individual who oversees the execution of a task or oversees the actions or work of others Trainer A qualified trainer in a compulsory trade is a journeyperson with a Certificate of Qualification or in a voluntary trade is an individual who is considered equivalent to a journeyperson with a Certificate of Qualification. TQAA Trades Qualification and ship Act Training Standard A document that has been written in concise statements that describe how well an apprentice must perform each skill in order to become competent. By using the document, trainers will be able to ensure that the apprentice is developing skills detailed for the occupation. 18

21 IMPORTANT DIRECTIONS For the 1. All complete skills or skill sets must be signed and dated by both the apprentice and the sponsor/employer when either all terms of the contract have been completed or the apprentice leaves the employ of the employer. 2. It is the responsibility of the apprentice to inform the local ship Client Services Office regarding the following changes: $ change of sponsor/employer address $ change of apprentice name or address $ transfer to a new sponsor/employer 3. The Skill Set Completion Form must be completed and signed by the current sponsor/employer and presented to the local ship Client Services Office at the fulfilment of all terms of a Contract of ship/training Agreement. 4. The Completion Form with the Completed and Authorized Training Standard must be presented to the local ship Client Services Unit. For the Sponsor/Employer and The Training Standard identifies skills required for this trade/occupation and its related training program. This Training Standard has been written in concise statements that describe how an apprentice must perform each skill in order to become competent. Competence means being able to perform the task to the required standard. By using this Training Standard, supervisors/trainers will be able to ensure that the apprentice is developing the skills detailed for the trade/occupation. Supervisors/trainers and apprentices are required to sign off on and date the skills following each successful acquisition. Sponsors/employers participating in this training program will be designated as the Signing Authority and are required to attest to successful achievement by signing the appropriate box included at the end of each skill set. 19

22 NOTICE OF COLLECTION OF PERSONAL INFORMATION 1. At any time during your apprenticeship training, you may be required to show this training standard to the Ministry of Training, Colleges and Universities (the Ministry). You will be required to disclose the signed ship Completion form to the Ministry in order to complete your program. The Ministry will use your personal information to administer and finance Ontario s apprenticeship training system, including confirming your completion and issuing your certificate of apprenticeship. 2. The Ministry will disclose information about your program completion and your certificate of apprenticeship to the Ontario College of Trades, as it is necessary for the College to carry out its responsibilities. 3. Your personal information is collected, used and disclosed by the Ministry under the authority of the Ontario College of Trades and ship Act, Questions about the collection, use and disclosure of your personal information by the Ministry may be addressed to the: Manager, Employment Ontario Contact Centre Ministry of Training, Colleges and Universities 33 Bloor St. E, 2nd floor, Toronto, Ontario M7A 2S3 Toll-free: ; Toronto: TTY: or

23 ROLES AND RESPONSIBILITIES OF THE APPRENTICE, SPONSOR/EMPLOYER, AND SUPERVISOR/TRAINER ship is a learning exercise. $ Practise safe work habits. $ Use your apprenticeship training standard as a journal to keep track of which skills you have achieved. $ Talk over your training plan with your Training Consultant, Employer, Union, or Sponsor. $ Know what tools are required for your trade and how to use them. $ Ask questions and keep asking. $ Talk to your employer about your training needs. $ Demonstrate enthusiasm and good work habits. $ Ensure that you and your supervisor/trainer sign off on skill/skill sets on demonstration of competency. Sponsor/Employer Training is an investment. $ Demonstrate safe work habits. $ Attest to successful achievement by signing off on the skill/skills sets. $ Provide opportunities and time for the apprentice to learn the trade. $ Offer practical trade training experiences that cover all the skill sets. $ Foster work ethics that support training while minimizing productivity losses. $ Set out clear expectations, then recognize or reward performance excellence. $ Involve both the apprentice and the supervisor/trainer in developing the training plan. $ Use the Training Standard as a monitoring tool and part of regular performance evaluations. $ Select supervisors/trainers who have good communication skills and who work well with others. $ Encourage supervisors/trainers to take upgrading courses (Train the Trainer, Mentor Coach, etc.). $ Complete the Skill Set Completion Form once the apprentice has demonstrated competency in the training. $ Ensure that the apprentice always works under the direction of or has access to a qualified supervisor/trainer. $ Vary the apprentice s exposure to all the skills set out in the Training Standard. 21

24 $ Demonstrate safe work habits. $ Treat apprentices fairly and with respect. $ Use the Training Standard as a guide to evaluating competence in each skill area. By using the Training Standard, supervisors/trainers will be able to ensure that the apprentice is developing skills detailed for the trade/occupation. $ Review the Training Standard with the apprentice and develop a training plan. $ Respond fully to all questions. $ Be patient. Explain what is to be done, then show how it is done, and then let the apprentice demonstrate the task. $ Provide continual feedback. $ Sign off on individual skills/skill sets once the apprentice demonstrates competence in the skill. Suggestions for Assessing the Progress of the in the Workplace $ Use informal daily observation. $ Provide constructive feedback to build confidence. $ Allow the supervisor/trainer time to teach and demonstrate the skills. $ Take prompt action whenever problems occur. $ Conduct regular performance reviews involving the apprentice, supervisor/trainer, and sponsor/employer. $ Use the Training Standard as the reference for establishing the competency of the apprentice. 22

25 SKILL SET COMPLETION FORM SKILLS SETS TITLE SIGNING AUTHORITY U PROTECT SELF AND OTHERS APPLY GENERAL WORK PRACTICES AND U PROCEDURES U PERFORM PRELIMINARY DIAGNOSIS U U U U U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) DIAGNOSE AND REPAIR FUEL CARBURATION SYSTEM DIAGNOSE AND REPAIR FUEL-INJECTION SYSTEM DIAGNOSE AND REPAIR COOLING SYSTEM DIAGNOSE AND REPAIR EXHAUST SYSTEM U DIAGNOSE AND REPAIR DRIVELINE DIAGNOSE AND REPAIR STEERING U SYSTEM DIAGNOSE AND REPAIR FRONT U SUSPENSION DIAGNOSE AND REPAIR REAR U SUSPENSION DIAGNOSE AND REPAIR MECHANICAL U BRAKING SYSTEM DIAGNOSE AND REPAIR HYDRAULIC U BRAKING SYSTEM DIAGNOSE AND REPAIR TIRES AND U WHEELS DIAGNOSE AND REPAIR CHARGING U SYSTEM DIAGNOSE AND REPAIR ELECTRIC U STARTING SYSTEM DIAGNOSE AND REPAIR IGNITION U SYSTEM 23

26 U U DIAGNOSE AND REPAIR ELECTRICAL ANCILLARIES DIAGNOSE AND REPAIR CHASSIS AND CHASSIS COMPONENTS U SERVICE BODY PARTS U DIAGNOSE AND REPAIR SIDECAR NOTE ON SHADED PERFORMANCE OBJECTIVES AND SKILLS $ Shaded performance objectives and skill sets are optional. The shaded skills do not have to be demonstrated or signed off on for completion of the on-the-job component of the apprenticeship. $ The in-school curriculum learning outcomes will cover all the skill sets, both shaded and unshaded. $ The Certificate of Qualification examination will test the whole of the trade and may test both shaded and unshaded performance skill sets. 24

27 U PROTECT SELF AND OTHERS GENERAL PERFORMANCE OBJECTIVES Protect self and others in the workplace by interpreting government and company safety standards and regulations, identifying health and safety hazards, and maintaining good housekeeping and working practices so that the workplace remains injury free, government and company safety and environmental standards are met, and all tools and equipment are maintained in safe operating condition. PERFORMANCE OBJECTIVES SKILLS U Identify health and safety hazards in the workplace, so that the potential for personal injury and damage to equipment, vehicles, and the environment are minimized, corrective action as defined in government legislation or company policies is taken, and hazards are reported. U Wear, adjust, and maintain personal protective equipment, such as eye, ear, hand, and foot protectors, so that safety clothing is correctly fitted and provides optimum protection to the wearer for the task being performed, including helmets, gloves, riding boots, and equipment necessary for the safe operation of a motorcycle. 25

28 U PROTECT SELF AND OTHERS (cont.) U Operate emergency safety equipment such as fire extinguishers, respirators, stretchers, and fire blankets to extinguish fires and administer first aid, so that procedures are carried out in safe, efficient manner in accordance with health and safety regulations. U Practise good housekeeping in the workplace by cleaning up oil spills, keeping work area clean and clear of obstructions, and storing tools so that the potential for accident or injury is minimized and tools and equipment are in place and available for the next job. U Operate and maintain tools and equipment in a safe manner so that vehicle damage and personal injury are prevented, and tools and equipment are kept clean and in good working order. 26

29 U PROTECT SELF AND OTHERS (cont.) U Ensure protection from fire hazards by keeping work area clear, identifying and removing potential fire hazards, and carefully handling explosive and flammable materials, so that hazardous situations and unsafe work practices are eliminated. U Handle and store hazardous materials, such as battery acid, brake dust, chemicals, and exhaust gases, using specified handling and storage equipment so that the technician is protected from injury and the environment from contamination, and so that procedures followed are in compliance with provincial and federal legislation. U Report injuries to supervisor or service manager promptly and efficiently, ensuring that the injured person is attended to, information is recorded precisely as to how incident occurred, and future recurrence of similar accidents is prevented. 27

30 U PROTECT SELF AND OTHERS (cont.) U Complete written safety and injury reports, following applicable safety acts and regulations, so that information for the Workplace Safety and Insurance Board and legal and insurance forms is complete and accurate and required deadlines are adhered to. U Apply basic first aid to treat conditions such as sudden illnesses, burns, cuts, abrasions, sprains, chemical inhalations, and contaminants in eyes, so that the condition of the victim is stabilized and he or she is prepared for transport to more advanced medical care facilities. 28

31 U PROTECT SELF AND OTHERS (cont.) U Identify unsafe vehicles by checking for damaged or defective components in the braking, steering, exhaust, fuel, and suspension systems, so that faults can be corrected and the vehicle can be restored to a safe operating condition. Sponsor/Employer Name Sponsor/Employer Signature 29

32 U APPLY GENERAL WORK PRACTICES AND PROCEDURES GENERAL PERFORMANCE OBJECTIVES Apply general work practices and procedures in the repair of motorcycles, including the development of effective customer relations, the selection and application of troubleshooting techniques, the access of technical information, the application and care of tools, equipment, and fastening and sealing devices, and the application of electrical wiring techniques, so that customers needs and expectations are met, an efficient and systematic diagnosis and repair procedure is followed, and repairs meet manufacturers specifications. PERFORMANCE OBJECTIVES SKILLS U Perform preliminary diagnosis, so that customers complaints are verified and documented using effective communication skills and correct use of industry terminology and ethical business practices, and a repair order is prepared that provides a precise agreement on repair procedures to be performed. 30

33 U APPLY GENERAL WORK PRACTICES AND PROCEDURES (cont.) U Access information in manufacturers service manuals and other related service materials, such as parts bulletins, service supplements, parts catalogues, and technical updates, so that service information and procedures are correctly followed. U Select, operate, and maintain hand, cutting, pneumatic, and electric power tools, so that the tool selected is the correct one for the application and manufacturers recommended operating and servicing procedures are followed. U Operate and maintain shop equipment such as cleaning equipment, hydraulic press, lifting and jacking equipment, hydraulic pullers, and air compressors, so that manufacturers recommended operating and servicing procedures are adhered to and the equipment is correct for the job being performed. 31

34 U APPLY GENERAL WORK PRACTICES AND PROCEDURES (cont.) U Operate and maintain dimensional measuring devices such as micrometers, calipers, gauges, straight edges, and dial indicators, so that an accurate measurement is obtained and devices are clean, calibrated, and stored to prevent damage. U Select, operate, and maintain oxyacetylene, arc, metal inert gas (MIG), and tungsten inert gas (TIG) welding equipment, so that metal surfaces are prepared for welding, personal protection equipment is worn or positioned, and voltage, amperage, gas pressures, and feeds are adjusted in accordance with manufacturers specifications and welding operations are performed in accordance with government and company safety regulations. U Replace fastening and sealing devices such as screws, bolts, rivets, nuts, washers, snap rings, lock-tite components, pins, seals, gaskets, and sealants, so that joined surfaces are fitted, secured, leak resistant, and meet manufacturers specifications. 32

35 U APPLY GENERAL WORK PRACTICES AND PROCEDURES (cont.) U Select and replace or repair electrical wires and connectors so that electrical/electronic integrity is maintained, electromagnetic interference is isolated, and all shorts and grounds are repaired. U Demonstrate troubleshooting techniques using electronic test equipment, onboard diagnostics, and service literature, so that faults are isolated systematically and repairs are performed according to manufacturers specifications. U Perform customer relations activities, including providing an honest interpretation of the vehicle s condition, explaining repairs and costs, providing a written statement of work performed, and resolving customers complaints so that customers expectations are met and information is communicated in a courteous and friendly manner. 33

36 U APPLY GENERAL WORK PRACTICES AND PROCEDURES (cont.) U Perform proper dismantling, logging, protection, and storage of parts in the proper order so that assembling is correct and coordinated as per manufacturers specifications. U Document measurements and defects noted during inspection, using computer and writing skills to convey the condition of the motorcycle to the client and the service team. Sponsor/Employer Name Sponsor/Employer Signature 34

37 U PERFORM PRELIMINARY DIAGNOSIS GENERAL PERFORMANCE OBJECTIVES Perform preliminary diagnosis of motorcycle so that customers complaints are verified and documented, a visual inspection and road test is conducted, and a repair order and estimate are prepared that provide a precise agreement on repair procedures to be performed. PERFORMANCE OBJECTIVES SKILLS U Conduct visual examination of motorcycle so that the general condition of the motorcycle and its related safety systems such as brakes, steering, and suspension can be assessed and requirement for road test can be determined. U Conduct a road test of the motorcycle so that the customer s complaint can be verified and an accurate assessment of the damage can be made in order for a written repair estimate to be presented to the customer for approval. 35

38 U PERFORM PRELIMINARY DIAGNOSIS (cont.) U Isolate problem to a specific part of the motorcycle using manufacturers recommended diagnosis procedures so that repairs can be made in an efficient and cost-effective manner. U Prepare preliminary written estimates that provides precise contracts on repairs to be made and obtains customers authorization to proceed with additional diagnosis, inspection, and repairs as per the provincial repair act. 36

39 U PERFORM PRELIMINARY DIAGNOSIS (cont.) U Prepare a written work order using effective written communication skills and ethical business practice that includes the work to be performed, the parts to be replaced, additional diagnostic requirements, and external repair services, and retain parts for owners or manufacturers inspection as per the provincial repair act. Sponsor/Employer Name Sponsor/Employer Signature 37

40 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINES (MECHANICAL) GENERAL PERFORMANCE OBJECTIVES Diagnose and repair two-stroke and four-stroke engines by performing tests such as a leak-down test, vacuum tests, a compression test, an oil-pressure test, and a crankcase pressure test, removing cylinder heads and cylinder block, visually inspecting and taking physical measurements of engine components, identifying and replacing defective components, and reassembling cylinder cases and cylinder block and head, so that the engine conforms to manufacturers specifications. PERFORMANCE OBJECTIVES SKILLS U Perform a visual inspection of engine externals, fuel, oil, coolant, and exhaust carbon leaks. U Listen to engine using an engine stethoscope so that abnormal internal engine noises such as knocks, rattles, grinding, and pings can be specifically located and identified. 38

41 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Remove spark plugs using wrenches and sockets so that condition of spark plugs, cylinder head threads, and spark plug seal washers and engine condition can be assessed. U Conduct compression and leak-down tests, using a cylinder compression gauge and leak-down tester, so that damaged or worn pistons, rings, cylinders, and valves can be identified. U Conduct crankcase pressure test using crankcase pressure tester so that the condition of crankcase seals, base gaskets, and head gaskets and the crankcase s porosity can be determined. 39

42 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Perform a visual inspection and functionally test oil-injection pump using tools, feeler gauges, wrenches, pliers, and screwdrivers, so that injector oil flow is determined and can be compared with manufacturers specifications. U Remove and visually inspect cylinder heads and cylinder mating surface using wrenches, sockets, straight edges, deadblow hammer, and feeler gauges, so that defects are identified. U Remove accumulated exhaust carbon from cylinder heads using a wire brush, a carbon scraper, air pressure, and engine cleaning solvents, so that the cylinder head s combustion chamber is free of carbon deposits. 40

43 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Resurface cylinder heads using cylinder head resurfacing equipment so that the cylinder head mating surfaces are free of scratches, scrapes, and warpage. U Remove cylinder block from crankcase using wrenches, sockets, and deadblow hammer so that pistons and related components are exposed. U Perform a visual inspection of cylinder components such as pistons, rings, wrist pins, and bearings, so that general condition can be determined and specific damage identified. 41

44 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Clean and measure cylinder components, such as pistons, piston rings, and cylinder bores, using tools and equipment such as wire brushes, scrapers, engine cleaning solvents, dial indicator, bore gauge, and micrometer, and compare the measurements with manufacturers specifications so components requiring repair or replacement can be identified. U Perform a visual inspection and physically measure intake reed valves and exhaust power valves using feeler gauges and vernier calipers, so that worn or damaged intake reed valves and exhaust power valves requiring repair or replacement can be identified. U Resleeve and resize cylinder using heat, hydraulic press, boring bar, hone, micrometers, cylinder bore gauges, and feeler gauges, so that damaged cylinder sleeves are removed and new cylinder sleeves are securely installed in cylinder block with sleeve bored out to meet manufacturers specifications. 42

45 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Deglaze cylinder bore using a cylinder hone so that internal cylinder surface is smooth, not pitted, and prepared to permit new piston ring seating. U Chamfer cylinder ports using a file so that the port edges will allow for smooth operation of piston rings. U Check and adjust piston ring end gap using feeler gauges and a file so that ring end gap meets manufacturers specifications. 43

46 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Remove engine from frame using tools such as wrenches, sockets, and screwdrivers so that the engine can be placed in work area, ready for disassembly. U Disassemble engine using wrenches, sockets, and manufacturers specialized tools, so that crankshaft and counterbalancer assemblies are removed from crankcases. U Disassemble, visually inspect, clean, and measure crankshaft components such as connecting rods, connecting rod bearings, flywheels, and crankshaft bearings using heat, hydraulic presses, bearing pullers, engine cleaning solvents, dial indicators, and vernier calipers, so that crankshaft parts can be cleaned, measurements taken, and those measurements compared with manufacturers specifications to identify parts that do not meet manufacturers specified wear limits. 44

47 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Perform a visual inspection of intake rotary valves for worn or chipped edges and scoring so that valves requiring replacement are identified. U Perform a visual inspection of crankcases, support bearings, and bushings for wear, corrosion, or damage so that components that require repair or replacement are identified. U Replace crankshaft components such as bearings, connecting rods, and flywheels, and rebuild crankshaft using crank aligning jig, dial gauges, and hydraulic presses so that the crankshaft is reassembled to the manufacturers specifications and prepared for reinstallation into the crankcase. 45

48 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Perform a visual inspection of counterbalancer components such as bearings, shafts, chains, and sprockets, so that damaged, worn, or corroded parts may be identified and requirement for repair or replacement determined. U Install counterbalancer and crankshaft in engine crankcases so that crankshaft and balancer timing marks are aligned and crankcase components rotate freely. U Reinstall intake rotary valve in crankcase so that correct fuel-intake timing is maintained. 46

49 U DIAGNOSE AND REPAIR TWO-STROKE AND FOUR-STROKE ENGINE (MECHANICAL) (cont.) U Reinstall internal cylinder components such as pistons, rings, wrist pins, and cylinder block using ring compressors, torque wrench, wrenches, and sockets, so that the engine is assembled in accordance with manufacturers service manuals and engine is prepared for reinstallation in motorcycle frame. U Reinstall engine in motorcycle frame using wrenches, sockets, screwdrivers, and pliers, so that the engine is secured in the frame with all control cables and electrical connections reconnected. U Bleed air from and adjust oil-injector pump including oil feed lines using screwdrivers, feeler gauges, wrenches, and pliers, so that the oil pump is adjusted to manufacturers specifications, oil lines are free of air, and oil is delivered to engine components during operation. 47